A/C Recovery Recycling and Recharge Machine EKM pluselcielektronik.com/doc/PLUS_İNG.A5.pdf · EKM...

A/C Recovery, Recycling and Recharge Machine

Operating And Service Manual

EKM plus

ENGLISH

Contents

Technical Specifications .........................3

Safety .....................................................4

Vehicle A/C System ................................5

Components ...........................................6

Control Panel .........................................7

Setup ......................................................8

Operations .............................................9

Recover Refrigerant .....................9

Charge Refrigerant ......................10

Recover from new tube ................16

Air purge .......................................17

Usage Information .................................17

Setting ....................................................18

Calibration .............................................20

Weight calibration ........................20

Vacuum calibration ..................... 21

Pressure calibration ..................... 22

Inverter ................................................ 23

Maintenance ....................................... 15

Compressor Maintenance ......... 24

Filtre change .............................. 25

Vacuum pump Maint. ................ 26

Troubleshooting .................................... 27

Warranty ............................................... 28

Warranty terms ......................... 28

Warranty certificate .................. 30

Suggestion ............................................. 31

About US ............................................... 32

Muniments ............................................ 33

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Technical Specifications

Model ....................................................... EKM PLUS

Refrigerant type ....................................... R134a

Power supply ........................................... 220 V ±10% / 50Hz

Display ...................................................... 4x20 character LCD

Storage tank capacity .............................. 6 kg

Scale resolution........................................ ±5 gr

Compressor .............................................. 1/4 HP 8 cc hermetic

Recovery rate ........................................... 250 gr/min maximum

Operating range ....................................... 8°C to 49°C

Low pressure gauge ................................. 15 bar

High pressure gauge ................................ 34 bar

Hose length .............................................. 180 cm (optional 250 cm & 300 cm)

Dimensions .............................................. 47 cm x 90cm x 57 cm

Weight...................................................... 62 kg

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Safety

Read this manual carefully and understand all the procedures outlines in this manual before operating the unit. Failure to follow these procedures could result in personal injury or property damage.

Allow only qualified personnel to operate this unit. The operator must have basic knowledge of air conditioning and refrigeration systems, including potential hazards associated with the handling of refrigerants and systems under high pressure.

Always wear safety goggles and appropriate protective clothing. Avoid contact of liquid refrigerant with the eyes and prolonged skin exposure.

Pressurized tank contains liquid refrigerant. Never fill the refrigerant tank to more than 80% of its maximum capacity. Hoses may contain refrigerant under pressure. Make sure to use a properly grounded AC outlet. Do not operate the unit with a damaged cord or plug. Extension cords should not be used unless

absolutely necessary. Disconnect unit from power supply before removing any protective cover. Do not expose the unit to wet environment. Only use the correct refrigerants. Avoid breathing in refrigerant vapors. Use only in well ventilated areas. The unit must be transported in a vertical position. The refrigerant scale must be fixed in place before transport.



Vehicle A/C System

COMPRESSOR : It increase pressure of refrigerant. Mean while refrigerant temparature increase too DRYER FILTER: The refrigerant which coming from radiator is dryed by the filter. Allows to pass liquid refrigernt through it and also Works a refrigerant tank in the system.

EVAPORATOR: An evaporator is a device in a process used to turn the liquid form of a chemical substance such as water into its gaseous-form/vapor. The liquid is evaporated, or vaporized, into a gas form of the targeted substance in that process.

CONDENSER: Role of this unit transition refrigerant to liquid state from gaseous state EXPANSION VALVE: A expansion valve is a component in refrigeration and air conditioning systems that controls the amount of refrigerant released into the evaporator thereby controlling superheat



Components

1 Pressure Gaugess 6 Dryer Filter 11 Compressor 2 On/Off button 7 İnverter (optional) 12 Condenser 3 Control Panel 8 Oil Seperator 13 Vacuum Pump 4 New oil bottle 9 Gas tank 14 5 Used oil bottle 10 Power Switch



Control Panel

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Setup

Unpack the unit and accessories. The package contains:

EKM PLUS unit

Low-side and high-side services hoses and quick-action coupler valves

Power cable

Operating manual and warranty manual

Before the first use:

1. Place the unit on a flat surface. 2. Connect quick-action coupler valves to the service hoses (DO NOT OVERTIGHTEN). 3. Remove aluminum foil from the vacuum pump and install oil filler

cap. 4. Remove fixing bolt located under the unit. 5. Plug the power cable into a grounded power outlet. 6. Turn on the power switch. 7. Perform a vacuum calibration (page 25).

WARNING: Scale is calibrated at the factory, re-calibration is not necessary.


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Operations

1- Recover Refrigerant The device draws gas from the air conditioning system of the vehicle, separates it from oil and particles, trap the passed acid and moisture through by the filter, purifies it and transfers it to its own tank.

1. Connect service hoses to the vehicle and open adapters. 2. Select REC FROM VEHICLE then press ENTER. 3. device will start recovering refrigerant from the A/C system. 4. If you see the warning OPEN USED OIL VALVE,

open used oil valve SLOWLY. 5. If you see the warning CLOSE USED OIL VALVE,

close used oil valve then press ENTER. 6. Screen will display PROCESS COMPLETE.

WARNING:

Some refrigerant will remain in the compressor, hoses or heat exchangers. The amount is dependant on the ambient temperature and last operation performed.

If you operate the vehicle until the normal operating temperature before operation, the gas in the air conditioning system will heat up and the duration of gas extraction from the car will be shortened. The vehicle A/C must be off.



Operations

2- Charge Refrigerant Uses to charge vehicle A/C system with refrigerant.

1. Connect service hoses to the vehicle and open adapters.

2. Select CHARGE REFRIGERANT then press ENTER. 3. There is two choice

A. MANUAL B. AUTO DATA



Operations

A. MANUAL

Operator must include the (vacuum time, Leak control, amount of gas) manually

1- VACUUM TIME Vacuum time entered to make the air conditioning system vacuum.

NOTE: The purpose of this process is to remove the air, water

vapor and other non-condensable gases from the air conditioning system.



Operations

2- LEAK CONTROL

The purpose of this operation is to see if the vacuum level is deteriorating.

1. Screen will display LEAK CONTROL TIME. 2. Use UP & DOWN buttons to set the desired time. 3. To skip leak control operation set the time to zero. 4. Press ENTER to proceed.

WARNING:

Unit will stop operation and screen will display LEAK IN SYSTEM in case of a leak.

Vacuum operation is required prior to Leak Control.



Operations

3- AMOUNT OF GAS

The purpose of this process is to enter the amount of gas we want to apply to system.

NOTE: in order to get better results we have to add gas (30-40gr.),

hose amount to the amount of gas we want to print .



Operations

4- Add New Oil

The purpose of this operation is to add new oil to the vehicle A/C system.

WARNING: Vacuum operation is firstly required to Add New Oil.

1. Screen will display ADD NEW OIL. 2. Use UP & DOWN buttons to select YES or NO. 3. Skip oil injection by selecting NO. 4. Press ENTER to proceed.

WARNING: Open oil valve when you see the warning on the screen.

Add the desired amount by watching cursors then

CLOSE OIL INJECTION VALVE. After closing the oil valve, press ENTER to proceed.



Operations

B. AUTO DATA In this option, the gas filling process will be done completely automatically.

NOTE: it is not necessary to add the amount of gas which is the hose

share in this process.

Vehicle Database

Select vehicle brand and model to charge vehicle A/C system with refrigerant.

1. Select VEHICLE DATABASE then press ENTER. 2. Use UP & DOWN buttons to select vehicle brand and model then press ENTER. 3. Unit will proceed with Vacuum, Leak Control, Add New Oil and Charge operations.



Operations

3- RECOVER FROM NEW TUBE

Add refrigerant to the storage tank.

WARNING:

Do not fill the own storage tank to its full capacity. Turn the external tank upside down to speed up the process.

1. Connect any one of the service hoses to the external tank and open tank's valve. 2. Open the valve of the connected service hose, close the other one on manifold. 3. Use UP & DOWN buttons to select REC FROM VEHICLE then press ENTER. 4. Unit will start transferring refrigerant to the own storage tank. 5. Operation will automatically stop when the storage tank is full or the external tank is empty. 6. Stop the operation by closing external tank's valve. 7. screen will display COMPLETED.



Operations

Air Purge

Excess air in the storage tank is purged. During recovery, air might be sucked into the storage tank with refrigerant due to leaks in the system. The unit will perform automatic air purge when sensors detect excess air in the storage tank. Operation time might differ depending on the amount of air in the tank.

Usage information

This menu contains the following information:

Last recovered amount

Total vacuum time

Filter usage

Tank refilled amount

Total amount recovered

Total amount charged



Setting

Press and hold ESC button on the main menu screen for 5 seconds to enter the calibrations and settings. To obtain a password, call the manufacturer service.



Setting

1- DATE / TIME

To adjust the date and time of machine.

2- DIL – LANGUAGE Turkish and English languages are registered in it’s own memory. User's request the desired language is loaded onto

3- SYSTEM VACUUMING It is a process used to vacuum the system

4- SERVICE( ciphered ) Uses to Usage reset, Tank capacity, Filter capacity and oil container setting



Calibrations

1- WEIGHT CALIBRATION

To do this, firstly we need an object that we know the net weight.

A. TARE: to reset the weight of machine own tank weight.

B. WEIGHT CALIBRATION: when you choose this menu it is automatically measured and the object which you know the weight of it, put it on the tank and press Enter to complete.

NOTE: the own tank must be completely empty.



Calibrations

2- VACUUM CALIBRATION

a. Select vacuum calibration option. b. For calibration open manifold valves and press ENTER. c. After a beep warning close the manifold valves and press ENTER. d. Machine automatically starts to countdown a timer and the number beside it also will

decrease to a certain number. e. After finishing the operation screen will display COMPLETED.



Calibrations

3- PRESSURE CALIBRATION

Select pressure calibration option

1. ZERO: By selecting this the pressure of machine is equalized to the atmospheric press.

2. GAIN: to perform this operation

Combine manifold outlets with a single hose and open manifold valves.

Charge 100 gr. Refrigerant Note the pressure of gauge Select the GAIN option. By using the arrows, insert the Pressure which you noticedbefore

in the bar section. To COMPLETE press Enter.



Inverter

İnverter (optional )

Since our EKM PLUS devices are portable land, mountain, etc. Where the electric power is not

available, is used to provide 220 volts of energy required for operation of the device.

Usage:

Attach the power cable of the device to the socket on the back of the device. Attach the RED wire of the inverter to the (+) side of the battery Attach the BLACK wire of the inverter to the (-) side of the battery start the vehicle engine Turn on EKM PLUS

Socket on the back of the device



Maintenance

Compressor Maintenance

Should be performed when screen displays CHANGE COMPRESSOR OIL.

1. Detach the hose from the drier filter to the compressor. 2. Use new oil bottle to fill in approximately 70 gr of oil with the help of TEST menu. 3. Re-attach the hose. 4. Go to main menu. 5. Press ESC for 5 seconds. 6. Select COMPRESSOR MAINTENANCE and press ENTER. 7. Screen will display COMPLETED.



Maintenance

Filter Change

Drier filter keeps recovered refrigerant clean and moisture free. Filter must be replaced periodically in order to ensure the unit is working properly. Using expired filters voids warranty. EKM plus filters need to be replaced every 100 kg of operation. After 80 kgs of operation, the unit will start reminding the user at every start up. When the filter reaches 100 kg, the unit will be locked.

1. Order a new filter. 2. Replace the filter. 3. Turn on the unit. 4. Hold ESC for 5 seconds. 5. Select FILTER CHANGE and press ENTER. 6. Use UP & DOWN buttons to write password then press ENTER.



Maintenance

Vacuum Pump Oil Change

In order to maintain pump efficiency, vacuum pump oil must be changed regularly. Contaminated oil might lead to irreversible damage to mechanical components of the vacuum pump. Change vacuum pump oil under the following conditions:

Every 30 working hours or when filter drier is replaced When the color of the oil becomes dark or cloudy 1. Obtain an empty container to collect the used oil. 2. Disconnect the unit from the electrical supply. 3. Unscrew the oil filler cap. 4. Unscrew the drain plug. 5. Allow the oil to drain out. 6. Close the drain plug. 7. Pour in new vacuum pump oil through the fill hole until mid level. 8. Replace oil filler cap. 9. Turn on the unit. 10. Press ESC for 5 seconds. 11. Select VACUUM OIL CHANGE to erase the warning.


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TROUBLESHOOTING PROBLEM CAUSE SOLUTION PROBLEM CAUSE SOLUTION

Unit does not

turn on

Power cord not

plugged in

Plug in the power

cord

Unit does

not charge

No refrigerant in tank Fill tank with

refrigerant

Power switch off Turn the power

switch on

Tank valve closed Open valve

Circuit breaker error Replace circuit

breaker

Service hose couplers

closed

Open couplers

No power in AC

outlet

Check power

source

Service hose

constricted

Straighten hose

Unit does not

recover

Manifold valve closed Open valve Leak in vehicle AC

system

Find and repair

leak

Service adapters

closed

Open adapters Scale calibration

error

Re-calibrate scale

Storage tank full Empty Storage Tank

Unit cannot

pull vacuum

Loose hose

connection

Tighten hose

connections

Vacuum calibration

error

Re-calibrate

vacuum

Leak in vehicle AC

system

Find and repair

leak

Weight

inaccuracies

Unit moving Do not move unit Oil injection valve

open

Close oil injection

valve

Storage tank touching

the unit

Prevent contact Leak in hoses Find and repair

leak

Contaminated

vacuum pump oil

Change vacuum

pump oil



Warranty

WARRANTY TERMS

1. Warranty period is (...) years and commences on the delivery date of the product.

2. The entire product except the hoses and the adapters is warranted by our company. 3. The warranty certificates without the sales date written by the seller/dealer and stamp and

signature are invalid. 4. If the product becomes defective within the warranty period, the time elapsed during repair

is added to the warranty period. The repair period of the product is maximum 30 (thirty) working days. This period starts as of the date the defect of the product is notified to the service station, or if a service station is not available, to any one of the product’s seller, distributor, agency, representative, importer or manufacturer. If defect of the product is not remedied within 15 working days, the manufacturer and importer must allocate another industrial product with similar functions to the use of the consumer until repair of product is completed. National, legal and religious holidays and weekends are not considered as working days.

5. If the product becomes defective within its warranty period due to faults of material and

workmanship or assembly, its repair shall be performed without demanding any charges as a cost of workmanship or replaced part, or by any other means.

6. Malfunctions taking place due to the use that is other than the ones stated in the operating

manual of the product will not be covered under the scope of the warranty.

7. The warranty will expire automatically whenever one of the following occurs: failure to perform maintenance; use of non-original spare parts, non recommended oils and/or gases; use of expired filters; use of unsuitable refrigerants and/or lubricants; damage caused by shocks, fires, or other accidental events.



Warranty

8. The manufacturer declines any and all responsibility for damage to vehicles on which recovery/recycling and recharging are performed if said damage is the result of unskillful handling by the operator or of failure to observe the basic safety rules set forth in the instruction manual.

9. This warranty does not cover damage arising during transportation. The product for which

repair under guarantee is requested must be shipped to the manufacturer under the customer’s exclusive responsibility.

10. The manufacturer shall not be responsible for any additional costs associated with a product

failure including, but not limited to, loss of work time, loss of refrigerant, cross-contamination of refrigerant, and unauthorized shipping and/or labor charges.

11. For the problems that may arise concerning the certificate of warranty, you may refer to the

General Directorate for the Protection of Consumers and Competition of the Ministry of Industry and Trade.

12. Even though the consumer uses its right of repair, if; As of the delivery date of the product to the consumer, within one year, provided that the

determined warranty period is valid; the same failure recurs more than twice, or different failures occur more than four times, or total of different failures within the determined warranty period is more than six, and also if these failures prevent benefiting from the product continuously;

The required maximum repair period is exceeded; It is determined that the defect cannot be remedied with a report prepared by the service

station of the company, and if a service station is not available, by any one of the product's seller, distributor, agency, representative, importer or manufacturer, respectively; the consumer may request the replacement of the product free of charge, or return of the cost or a discount in the cost at the rate of defect.



Warranty

WARRANTY CERTIFICATE

MANUFACTURING COMPANY

TITLE ELCİ ELEKTRONİK KLİMA SANAYİ VE TİCARET LTD. ŞTİ.

ADDRESS İVEDİK ORGANİZE INDUSRIAL REGION WOOD WORKING SITES

1354. STREET. 1357. Qr. NO: 30 YENİMAHALLE / ANKARA / TÜRKİYE

TELEPHONE +90 312 395 53 53 (PBX)

FAX +90 312 395 18 86

PRODUCT

TYPE REFRIGERANT RECOVERY RECYCLE RECHARGE MACHINE

BRAND ELCİ

MODEL EKM PLUS

SERIAL NUMBER ................................................

PLACE AND DATE OF DELIVERY ................................................

WARRANTY PERIOD ................................................

MAXIMUM REPAIR PERIOD 30 WORKING DAYS

DEALER OR DISTRIBUTOR COMPANY

TITLE ................................................

ADDRESS ................................................

TELEPHONE ................................................

FAX ................................................

INVOICE DATE AND NUMBER ................................................



Suggestion

Gases and oils recommended by the manufacturer;

Refrigerant: Tazetti Solkane AG Adge Arkema Honeywell Chemours

Compressor oils:

PAO compressor oil Reniso PAG Reniso Triton SEZ 68 POE Reniso Triton SE 170 POE

Vacuum pomp oils: ELCİ vacuum oil Value vacuum pomp oil.



About Us

ELCİ Electronic Air Conditioning Industry Trade Limited Company was founded in 2003 and has become the leader in the production of Air Conditioning Service Stations in a short time.

Since its foundation, ELCİ had contributed to continuous development with production according to Turkish Standards and European norms.

We are awarded with ISO 9001:2008 that has the validity all around the world and CE certificate that satisfies all quality and safety requirements necessary for European Union (EU) countries.

Our customer oriented management system and continuous research and development activities enable us to offer the best price to meet the expectations of the customers at highest level, without compromising the quality. From design to after sales in every stage of production, we are contributed to Total Quality Management System.

The first full automatic recharge station in Turkey was developed and produced by ELCİ in 2003 with a great success. And in 2013 another milestone in the company’s history, is the design and production of the first recharge station operating by a tablet via Bluetooth technology. From the beginning, our experienced team dedicated to follow the technological developments to produce more user friendly products for more environmentally friendly world.



Muniments

SERVICE QUALITY DOCUMENT ISO 9001:2008



Muniments

BRAND RENEWAL CERTIFICATE CE DECLARATION OF CONFORMITY



NOTE

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A/C Recovery Recycling and Recharge Machine EKM pluselcielektronik.com/doc/PLUS_İNG.A5.pdf · EKM...

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